Die cutting has been part of the manufacturing process throughout the majority of the 20th century. It is the process of shearing low density materials into a specific shape. Materials which can be die cut include rubber, foil, paper, cloth and even plastic, paperboard, foam, sheet metal or leather.
Cutting is completed on either a flatbed or a rotary press. Flatbed presses tend to be the preferred choice for those with a small production run or less budget available for the manufacturing costs. Rotary presses are much faster and can handle much bigger, complex cutting jobs. They work by having two cylindrical presses; the material to be sheared is threaded between the presses and cut into the required shape as it passes through the press. The press can repeat the pattern over and over again on the same material; this makes it excellent for bigger production runs, despite the additional costs involved in running one.
These machines are highly efficient and precise; a fact that has made the technique come to the attention of a variety of businesses. Medicine and patient treatment is one area that has become exceptionally interested in the capabilities of the die cutting machine. The accuracy is essential when producing medical equipment. Of course, medical equipment and parts for the human body need to be completely sterile; this is to ensure bacteria and disease are not inadvertently placed inside people. To ensure this is the case the entire production process must be carefully controlled.
The first step in this is to create a clean room for die cutting. Sterile material can then be brought into the room and processed to make a specific product. This product is created, packed, sealed and then boxed, all before it leaves the clean room. This ensures the product arrives at its destination completely sterile. A cleanroom die cutting machine needs to be carefully cleaned and sterilized by highly trained cleaners; it must also be kept in a sterile, temperature and air controlled environment. There are several businesses which offer this service; if you are interested in using the services of a firm such as Baril Corporation, it is essential to check the company out and ensure they meet all the relevant standards. They have been offering a cleanroom for die cutting for many years and are acknowledged as one of the best in the business.
The popularity of this technique is increasing rapidly; there are several reasons for this:
- Increase in demand for Medical Supplies
When die cutting was first started as a production process there were no cleanroom facilities, even the concept of a clean room was alien! As the cutting techniques improved, so has the awareness of the importance of sterile parts and equipment to the medical professions. This awareness created a need for cleanroom die cutting as an affordable, practical solution to the needs of the medical profession.
As medical technology has advanced, people are living longer and needing medical treatment for longer. The rapid increase in the older population has created a huge increase in the need for many medically related products. All these products must be created in a sterile environment and these contribute to a massive increase in demand.
- Production Costs Decreasing
As with any technology, the older it becomes and the more it is both used and needed the cheaper the equipment becomes. This is normal in any technological field. New techniques and equipment will always be more expensive until enough supply is available to enable the manufacturers to purchase parts in bulk and build cheaper machines. The savings in purchasing and efficiency costs can be passed onto the customer. In effect, the more the demand increases for the use of this process, the cheaper and cheaper it will become!
- Improvement in Cutting Techniques and Materials Which Can be Cut
Another reason that cleanroom die cutting has become more popular is the improvement in the range of materials which can be cut on these machines. Technology is constantly improving; these improvements have enabled die cutters to operate on a vast array of material, which was previously not possible. The larger the range of material which can be cut via this process the more people who are interested in using this technique. This increase in the production possibilities encourages mote people to use the machines.
Alongside this there have been improvements in the efficiency of the machines and the amount of wastage created. This serves to reduce production costs making the product produced by these machines even more affordable; and therefore more attractive to buyers.
- Easier Access to Manufacturers; More of them Available
As with any commercial enterprise, the more successful a process becomes the more interest is generated in it. Increase in production possibilities and a reduction in production costs and even machine purchase costs, has attracted more businesses into the field of die cutting. The increase in manufacturers using this process then leads to more choice and more competitiveness between the manufacturers. This situation is extremely beneficial to those looking to use the services of a cutting machine, the more manufacturers there are, the bigger the customer base becomes. It is a continually growing process, particularly when one of the biggest customers of the cleanroom die cutter is the medical profession and their needs, supported by governments, are on the increase!
- Out sourcing
An additional reason as to why die cutting has become far more popular in recent years is the increase in outsourcing by many firms. If a hospital outsources their medical supplies need then a third party is looking to purchase the products they need and supply them to the hospital whilst still making a profit themselves. This is only possible if they manage to win contracts to do, this for several hospitals. They can then approach the manufacturers and negotiate cheaper rates, creating their profit. This increases competition and keeps prices down, enabling non-related parties to get a good deal. More importantly it opens up the way for these middle companies to look for more applications for the die cutters and expand their businesses. Their search for customers will increase the number of businesses using cleanroom die cutting and cause the industry to grow!
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